I’m making a “MERRY CHRISTMAS” sign for the yard. Letters are approximately 2 ft tall and will contain around 100 lights per letter. Used select grade poplar. Letters will be white with alternating red and green LED lights. Therein lies my main concern. The holes for the lights. See attached photos for reference. I made an “E” for test. I’m concerned the exposed wood in the holes for the lights to go in will expand/swell in the weather. (Kansas). Not only might it cause cosmetic/integrity issues but might actually crack the lights depending on how much it swells. However I’m not sure how to get paint into the holes adequately, if it’s even necessary or if I’m just hoping it’s not because I’m not excited about the approximate 1400 holes I’m looking at. Any help or advice would be much appreciated.
Replies
The wood is thin, and the holes small. You'd need a micrometer to measure expansion and contraction. I wouldn't worry about it.
The letter looks great.
If you really want paint in the holes go with a pipe cleaner. Wear a tarp.
I'd use rattle can paint for this project and get as much in the holes as you can, but not obsess with it. But I'd expect any outdoor thing like this to only last a few years anyway.
Don't worry about expansion cracking the LEDs; they can take it.
A suggestion ............ in case anyone is thinking along these lines, last year I did a shadowbox (wife's idea, giving credit where due) to go in the window above the garage door.
A simple box of 1/2" plywood, with a 1/4" plywood back. The 1/4" holes for the LEDs were drilled in the back and were evenly spaced to light up the white painted interior. The lettering and dove were cut out on the scroll saw. A large sheet of thin white paper glued to the inside of the front diffuses light and hides the glare of the LEDs. The 3 sets of LEDs are battery powered and come on for 6 hours and off for 18.
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